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Licensed Under Creative Commons Attribution CC BY Study on Forging and
Forming, Intelligent Production Robot System for an Automotive Component
Article in International Journal of Science and Research (IJSR) · October 2020
DOI: 10.21275/SR20919022617
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International Journal of Science and Research (IJSR)
ISSN: 2319-7064
ResearchGate Impact Factor (2018): 0.28 | SJIF (2019): 7.583
Study on Forging and Forming, Intelligent
Production Robot System for an Automotive
Component
Orelaja Oluseyi .A*a,b, Michael Bola Adelekeb, Ishola A. Afizc, Odutayo Oladipob, Olufemi Peter Kehinded,
Abiodun Olakunle Israelb
a
School of Mechanical Engineering, Southeast University, Nanjing, PR China.
b
Department of Mechanical Engineering, Moshood Abiola Polytechnic, Ogun State, Nigeria
c
Department of Mechanical Engineering, Federal University of Agriculture Abeokuta, Ogun State, Nigeria
d
Department Electro-Mechanical Maintenance (SMD),British American Tobacco, Ibadan Oyo State Nigeria
Abstract: This paper describes a detailed concept of Hot Forging and forming intelligent production techniques as currently practiced
in the forging and forming industry.Automobile industries has been relatively resistant to handling automation because of the severe
challenges that are faced by having typically small batch sizes, extremely challenging operating conditions in terms of temperatures and
pressures and lighting conditions. This paper however, discusses how aspects of these difficulties can be overcome and it is hoped that
the specific solutions and methodology presented will find general applications in other aspects of manufacturing industry. The concept
of the ‘‘Automated Forging of the Future’’ is also introduced in which advanced handling such as rapid tooling-change and flexibility,
smart metrology, advanced sensing and intelligent gripping techniques are presented. The concurrent objective of optimizing materials
performance by manipulating materials structure for example, hardness and strength by the automated forging processes is
analyzed,this concept represents the distillation of work on automated forging based system.
Keywords: Automation, Robotics, Forging, Forming,Hot, Industry, Automobile, Smart, Manufacturing
1. Introduction be used to explore discrete simulation approaches, especially
where hard production data exist on Tact time, time in
The manufacturing forging industry can be grouped across process, batch sizes and other production data can refine the
several industries including Automotive, Aerospace and investment proposition. Academic work on forging
Medical being used by relatively high value added operation. automation is relatively sparse, however case studies can be
Continual cost pressures have meant that industries needed found which illustrate the public face of successful
to work smarter rather than harder, since lower costs bases implementations according to Eleftheriou [6]. Systems
attract plug or fits compatible manufacturing replication, simulation for automation can be applied particularly where
unless there is a high skill, higher value-add differentiator[1]. the implementation includes data on queuing, mean time
Smart automation is presented as one of the factors that between failures (MTBF) and mean time to repair (MTTR)
differentiate and the ability to quickly change over between though the results tend to be general in nature. One possible
batches, achieve higher manufacturing tolerances and approach when considering a large investment in
overall quality, and however in many cases increasing forging/forming particularly due to the high cost, and
volume have been key drivers for the implementation of longevity of press technology, is often to simulate the
advanced automation. Typical product families that have process in order to clarify in detail how the modified
been automated include the production in the automotive operation will work and this can then be verified in broad
industry of gears, hubs, crankshafts with the main objective brush terms with a cost modeling approach in order to
of improving materials performance by manipulating quantify the benefits. Forging presents a tremendous
materials structure for example, hardness and strength by the challenge to the systems integrator wishing to build in
automated forging processes themselves[2]. The key automation to the manufacturing process, combining as it
advantages that are presented for automation include: (1) does the effects of varying temperatures, immense
Increased Volume (capacity),(2) Improved Quality – via potentially destructive forces, and accumulations of
consistency of manufacturing and reduction in variability hardening lubricant. The Forging Industries Association
and [3]Costs reduction, that is the reduction in dependency Technology Plan [7]has identified a number of key issues
on hard to find labor to work in harsh operating conditions that need to be addressed which prioritizes process control
and [4]Improved Safety Occupational health statistics and modifications of the „„Hoteye‟‟ system and other
implementation in order to continue to illustrate that sensing data for Forging.
powered presses are a major source of industrial accidents.
A widely used system is based on manufacturing systems The key objectives of this research work are mainly the
simulation allied to a cost benefit analysis in order to adopt a advantages that the automation of the forging process brings
relatively low cost approach, which is the initial business which include the following:
benefits. Systems such as Witness Hocus[5], and the like can a) Increased Volume (capacity).
Volume 9 Issue 10, October 2020
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Licensed Under Creative Commons Attribution CC BY
Paper ID: SR20919022617 DOI: 10.21275/SR20919022617 38
International Journal of Science and Research (IJSR)
ISSN: 2319-7064
ResearchGate Impact Factor (2018): 0.28 | SJIF (2019): 7.583
b) Improved Quality – via consistency of manufacturing 2.1 Automation for forging applications
and
c) Reduction in variability. 2.1.1 Automated robotic handling
d) Reduced Costs. A key factor in automated handling for forges is the use of
e) Reduced dependency on hard to find labour to work in robots and the following section places in this context. The
harsh operating conditions. British Automation and Robot Association [8]publishes an
f) Improved Safety Occupational health statistics annual review on robot use based on feedback from 40
continueto illustrate that powered presses are a major leading suppliers [4, 8]which reports that the market is
source of industrial accidents. dominated by automotive applications, and recent statistics
suggest there are 25,000 robots in service .However the use
2. Methodology of robotics in forging and is one that is increasing from a
relatively low level depending on category definition (see
The path followed for the methodology of this research Figure 1) and the non-automotive applications have
paper has been to make a detailed survey the existing continued to grow. It is estimated that 75% of installed
methods. This was though sparse academic literature, robots are of the 6 axis type (BARA-2009) figures. An
interview with Industryand machine operators and to vividly approach to adopting automation by subdividing the process
examine the related case study. The first task was to define (of handling) the following operations:
what is meant by automationin forging process and this
description is sufficiently show that a number of modular a) billet loading and trim press loading
topics can be included in our findings which include: b) parts transfer robot and spray robot
Automated handling, c) parts transfer robot
Automated lubrication, d) spray robot
Automated heating,
Automated process control.
Figure 1: UK Robot application analysis for 2009[8]
This approach could be described as„„Robotizing the
man‟‟[9]. A more fundamental approach which relates more
to the state of the art is a system such as that promoted by
Schuler Automation[10]involving a completely integrated
transfer press line. This system uses a fully enclosed
approach and a central drive to co-ordinate manufacture (see
Figure 2). The part handling is achieved internally by using
a modular lever transfer arrangement in order to handle
formed panels between each individual press station. A
variety of handling systems are available such as cross
Figure 2 .High volume “Compact” Automotive cross bar
shuttles, robot loading with conveyors, and independently
press (Schuler Automation)
controllable feeders depending on the client automation
needs. Here the robot is mounted on a rail system and it
travels between sites whilst the part is still held (see Figure
3).
Volume 9 Issue 10, October 2020
www.ijsr.net
Licensed Under Creative Commons Attribution CC BY
Paper ID: SR20919022617 DOI: 10.21275/SR20919022617 39
International Journal of Science and Research (IJSR)
ISSN: 2319-7064
ResearchGate Impact Factor (2018): 0.28 | SJIF (2019): 7.583
d) Improved safety and environmentally friendly through
lower energy costs, typical productive life.
2.3 Type of Robot used in Automobile and Forging
Industry
The introduction of Automation in forging clearly has a
number of specific challenges, because of the prevalence of
high temperatures (up to 1100 C for some materials) and
airborne detritus means those exceptionally robust robots are
used, often incorporating specially adapted grippers [12].
This system has been installed by DIC Engineering as part
of a crankshaft line for General Motors incorporating an
NKMZ 7000T forging press, with piezoelectric load cells to
Figure 3: “Crossbar Robot” transfers part directly from protect against overload. It should be possible using a robot
press to (Scheler Automation) spray technique to generate a relatively sophisticated dag
spray pattern that only operates where it is absolutely needed
2.2 Advantages of Robotic handling using a modified lance rather than in the general area of the
part and tooling see Fig.4 (a and b) below. Automatic
Typical advertised benefits of robotic handling include[11]: lubrication systems are often a part of the forming process –
a) Improved consistency usually named „„dagging.‟‟ This will result in less dag being
b) Greater production volume and reduced labor- hours applied together with reduction in the associated cooling
c) Safer operation, and lowered production costs effects; fig .5 reveals the use of dagging in extrusion and
heading.
Figure 4 (a and b) Standard 6 axis Robot model IRB 7600for handling crankshaft for Auto-Industry [12]
Figure 5: Dag application in Extrusion and Heading (Mc.Intosh)
Volume 9 Issue 10, October 2020
www.ijsr.net
Licensed Under Creative Commons Attribution CC BY
Paper ID: SR20919022617 DOI: 10.21275/SR20919022617 40
International Journal of Science and Research (IJSR)
ISSN: 2319-7064
ResearchGate Impact Factor (2018): 0.28 | SJIF (2019): 7.583
3. Research Challenges in Forging Automation 4. Vision for Automation
3.1 Non-specific automation process challenges This is to achieve the following:
To generate a stable repeatable platform for forging and
It is important to have a high understanding of the detailed forming trials/experiments.
nature of the task that requires automation in order to be able To generate and prove out automation forming
to specify and implement an automated system. Barriers to techniques which have a 5–10 year technical benefits
implementation can include fear of redundancy [3] and labor lead on existing industrial practice.
displacement – though in practice robotic automation tends
to mean that existing staff are redeployed into other areas 4.1 Design considerations
after an increase in volume and quality has been achieved,
though some of those who leave voluntarily may not be As part of the implementation of the Automation Capability
replaced. Automation in general has a range of challenges a Forge working processfor example in a typical robotic
but forging presents some that rare relatively uncommon. orientated cell a pick and place robot would be positioned
There is a market led desire to move towards small smaller front and center (or slightly offset due to the geometry of the
batch sizes[13] and the case for automation may mean that robot joints) in a permanent floor position, meaning
the technical aspects of implementation cannot easily be difficulties for both access and interoperability as shown in
demonstrated ,therefore technical achievability influences Fig. 6.
the benefits. The major long term strategic challenge
involved is that of worker substitution[14]. The original
source of the word robot [15], particularly applicable in a
hostile environment such as a forge or foundry operations
involving high temperatures, levels of contamination, and
extremely powerful machinery.
3.2 Process specific challenges
Hot Forging in particular means that handling equipment
must be designed to cope with metallic materials at up to
1100 C, so replaceable, robust handling systems such as
gripper jaws are one possible solution for long term use.
Cold and warm forging often means a commensurate
increase in forging forces. The idea that fragile dexterous
robot hands can be used is not one that finds implementation
Figure 6: Design of Special Intelligent Manufacturing
in practice. Hence smart techniques for advanced handling
Robot Tool- Layout checking
or sensing must be sufficiently robust as to cope with locally
high temperatures.
5. Types of Automation in Intelligent Forming
3.2.1. Handling flash/excess material and Forging
Forging and forming processes often produce small but
important amounts of waste or excess flash material either 5.1.1. Furnace heating – automation
after clipping or as part of the extrusion process. One The AFRC rotary furnace device includes an incrementing
objective of the forming process is to improve the material hearth which can be moved round to the next position for
parameters by using the deformation process and thus the presentation to the operator or robot.
idea is to do the minimum possible machining.
5.2. Screw press – automation
3.2.2. Press integration
Integrating with existing manufacturers presses presents Here the screw press needs to be controlled remotely by a
major challenges and one approach is to go back to the master PLC in order to execute pre-programmed load
original manufacturer, or specifically the press controller. conditions and press stroke. Some thought needed to be put
Presses have long lives typically 50 years+ but much longer into what would happen if a part is stuck in the tooling, as
are not unusual – with upgrades in controllers in order to well as into making sure that appropriate communications
interface with advanced metrology. Fortunately we have protocols are put into place and thatfacilities exist to interact
skilled expertise that can deal with this, skills which are with the master PLC, see Fig. 7 and Fig.8.
often employed by the systems integrator, including the
critical safety elements, safety interlocks, guarding as
required [16-18]. Often once the press project moves
forwards snags occur, such as dealing with the waste
product (flash) created when parts are reduced in volume –
failure to do this will jam the tools, as well as how parts that
stick in the tool are to be removed.
Volume 9 Issue 10, October 2020
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Licensed Under Creative Commons Attribution CC BY
Paper ID: SR20919022617 DOI: 10.21275/SR20919022617 41
International Journal of Science and Research (IJSR)
ISSN: 2319-7064
ResearchGate Impact Factor (2018): 0.28 | SJIF (2019): 7.583
Advantages
The standard workspace is clear and the robot could be
parked safely well away from the press when not in use. The
robot could be repeatedly placed in a centralized position
when required. The working envelope of the robot and its
flexibility would be enhanced considerably.
Disadvantages
Due to the increase in the cost and increased complexity in
programming of (7th axis), however these disadvantages
were greatly enhanced by the increased flexibility –
especially important in an R&D environment where the
ability to change over from task to another and to implement
small batch sizes is critically important. Fig.9 illustrates how
the location and handling arrangement is to be checked so
that the robot could be placed in an ideal park position, and
Figure 7: Robot operating inside press tooling deployed in front of the Programmable furnace, screw press
and clipping press.
Figure 8: Checking clearance of robot and park position
Figure 9: Show Robot interactions with press
5.2.3. Safety protocols/guarding
Legislative requirements and basic consideration for staff 5.2.1. Trimming/clipping press
safety dictated at an early stage that safety guarding had to At the output side of the screw press, a clipping press has
be included. Since even the smaller robot (overall mass 140 been placed which removes any final waste from the final
kg) is capable of moving at up to 600 per second it does stamped part. From the Automation engineers view both
have the potential to cause some damage both to staff and presses can be regarded as similar devices – in which
itself and auxiliary equipment. Guards were therefore program control is handed over to the individual press
procures and installed Final layout is also important upon controller, which then has load displacement parameters
placement of the multi-forge/horizontal up-setter and required for a particular part sequence as seen in Fig. 10
integration of the guarding to cope with both the position of below
that in the one manufacturing cell.
Figure 10: Funuc M710 Robot mounted inverted on Gantry for Trimming /clipping press
Volume 9 Issue 10, October 2020
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Licensed Under Creative Commons Attribution CC BY
Paper ID: SR20919022617 DOI: 10.21275/SR20919022617 42
International Journal of Science and Research (IJSR)
ISSN: 2319-7064
ResearchGate Impact Factor (2018): 0.28 | SJIF (2019): 7.583
5.2.2. Automation in practice [5] Harrison, C.S., Ross,I.G,, BellJack,M., McEwan,P.W.,
As the development of the automation work is progressing it Manual on manufacturing systems simulation for NCR
became imperative that the experimental interest and Dundee, . 1989, University of Dundee,(unpublished).
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situations excited research interest,. Although, more project turbine Compressor Blades from billet to finished
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automated handling system was not designed for this from facts_2010.pdf.
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been achieved, though some of those who leave voluntarily
may not be replaced.
6. Conclusions
This paper has described the process of
intelligentmanufacturing and smart automation as related to
forging and an outline of a process to design and
implementation of an automated robotic forging cell, based
on a large press. The process requires clear management
support from the beginning as well as a realization that for
certain applications smart design can accommodate both
manual forging and automated forging operation using the
same installation. A micro-management approach to the
process is required that includes all the corrective actions
that intelligent operators do in order to produce smart
forgings and the process of laying out the cell has been
described, using CAD tools including Robo-guide, and Pro-
Engineer. This serves as a basic structure for flexible
technology development in the manufacturing industries.
References
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mode hot forging. Manufacturing Review : EDP
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rolls%20royce,Automated forging of Gas turbine
Compressor Blades from billet to finished forging. 2020.
[3] Channel and J.C.b.E.h.w.y.c.w.v.W.R. Series 9 Episode
3 segment D.
[4] Professional Engineering, I.o.M.E. and 27. 2014.
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